Energy generating modules with fuel chambers

ABSTRACT

A fuel module comprises an enclosure and a fuel chamber. In one exemplary embodiment, the fuel chamber comprises a primary containment tank contained within a secondary containment tank. The enclosure comprises a plurality of exterior enclosure walls and a plurality of interior enclosure walls that cooperate to form the secondary containment tank such that the primary containment tank is disposed between the exterior enclosure walls and the interior enclosure walls. In another exemplary embodiment, the exterior enclosure walls and the interior enclosure walls cooperate to form a single-walled fuel chamber disposed between the exterior and interior enclosure walls of the fuel module. Additional exemplary embodiments include fuel chambers configured as any multiple-wall structures, whether double-wall, triple-wall, or other, that comprise a plurality of containment tanks.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is filed under 35 U.S.C. 111(a) as acontinuation-in-part of U.S. patent application Ser. No. 12/205,421filed Sep. 5, 2008 (U.S. Pat. No. 7,589,429), which is a continuation ofInternational Patent Application No. PCT/US08/72096, which internationalapplication designates the United States and claims the benefit of U.S.Provisional Application Ser. No. 60/970,417, filed Sep. 6, 2007.

BACKGROUND

Conventional power generating systems generally are used to generateelectric power either in remote areas where access to electricity islimited or in urban areas to provide backup power during power outages.More particularly, such conventional systems typically utilize a dieselengine to generate the needed electric power, which may be used for bothprime (primary source) and backup (redundant source) power. Powergenerating systems commonly are used for industrial, construction,mining, oil and gas exploration, and other commercial applications. Forexample, for industrial applications, the systems may be used to supportprime and/or backup electric power for factories; for construction,mining, and oil and gas exploration applications, the systems may beused to generate prime power for the operation of equipment, given thatthe locations of such activities often are too remote and distant frommunicipal power grids; and, for commercial applications, the systems mayprovide backup electric power for electrical systems should themunicipal power grid temporarily lose power due to a storm, naturaldisaster, sabotage, etc.

Power generating systems typically generate significant amounts ofnoise, are very expensive, and may be transportable from one location toanother. As such, power generating systems generally are enclosed inorder to reduce the amount of noise escaping to the surrounding outsideenvironment, to protect the engine and other components from theft andenvironmental conditions, and to facilitate their transportation. Acommon enclosure for power generating systems are standard shippingcontainers, such as ISO (International Organization for Standardization)shipping containers. Enclosure of power generating systems within suchcontainers enables the systems to be easily and rapidly deployed tovariously located job sites. Another common enclosure for powergenerating systems are drop-over enclosures that may be designed in avariety of dimensions and configurations. Drop-over enclosures typicallyare used for power generating systems intending to have a fixedlocation, such as atop a commercial building.

Depending upon the unique customer requirements, which, in large part,may be dictated by federal, state, and local laws, additional equipmentmay be needed to operate and support the power generating systems. Thisequipment may include, but is not limited to, the following: DC lightingsystems, electrical controls such as switchgear or a voltage changeoverboard, sound attenuation, fire suppression systems, personnel doors,fuel tank, louvers for ventilation, and an exhaust system. With thefootprint of the enclosure often being constrained, due to the powergenerating system's proximity to buildings, equipment, etc., designersof power generating systems may seek to minimize the dimensions ofinternal components of the power generating system, including theengine, such that the overall footprint of the enclosure may beminimized. Alternatively, when using a standard shipping container, theoutside dimensions are fixed. Therefore, all of the required componentsmust be sized so as to fit inside of the container.

Power generating systems using liquid fuels, such as petroleum-basedfuels, may present problems in attempting to minimize sizes of necessarycomponents. For not only must fuel tanks meet all federal, state, andlocal laws, but fuel tanks must also fulfill the engine's fuel supplyrequirements within the available space of the enclosure. Therefore,there is a desire to maximize the size of the fuel tank in order reducethe frequency of necessary and costly re-fuelings of the powergenerating system that competes with the desire to minimize the size ofthe power generating modules and their components.

Further, conventional fuel tanks are designed and built in cylindrical,square, and rectangular shapes as discrete components connected to theengine via tubes and hoses. Given the size and shape of existing liquidfuel engines most commonly used, designers generally must install thefuel tank in the nose (front), in the tail (rear), or beneath theengine. If the fuel tank is to meet Underwriters Laboratories' standardsfor fuel containment, then the fuel tank must be double-walled such thatif an exterior wall is pierced, an uncompromised interior wall preventsthe fuel from leaking. Also, conventional fuel tanks may create unevensurfaces within interiors of the power generating systems, particularlyin workspace areas. For example, if a fuel tank is positioned below theengine, its exterior walls may create a trip hazard and/or create unevenfloor or wall surfaces, making it more difficult for a designer tooptimize space within the interior of the power generating system.

SUMMARY

Embodiments of the present invention relate generally to energygenerating modules. More particularly, embodiments relate generally toenergy generating modules that comprise an enclosure, an energygenerating device, and a fuel chamber, wherein exterior walls andinterior walls of the enclosure cooperate to form the fuel chamber suchthat the fuel chamber is disposed between the exterior and interiorenclosure walls.

In accordance with one embodiment, a fuel module comprises an enclosureand a fuel chamber. The fuel chamber comprises a primary containmenttank contained within a secondary containment tank. The primarycontainment tank of the fuel chamber comprises one or more cellsconfigured to contain fuel. The enclosure comprises a plurality ofexterior enclosure walls and a plurality of interior enclosure walls.The exterior enclosure walls and the interior enclosure walls cooperateto form the secondary containment tank of the fuel chamber such that theprimary containment tank is disposed between the exterior enclosurewalls and the interior enclosure walls.

In accordance with another embodiment, an energy generating modulecomprises an enclosure, a fuel chamber, one or more sealable ports, andone or more fuel sensors. The fuel chamber comprises a primarycontainment tank contained within a secondary containment tank. Theenclosure comprises a plurality of exterior enclosure walls and aplurality of interior enclosure walls. The exterior enclosure walls andthe interior enclosure walls cooperate to form the secondary containmenttank of the fuel chamber such that the primary containment tank isdisposed between the exterior enclosure walls and the interior enclosurewalls. The primary containment tank of the fuel chamber comprises one ormore cells configured to contain fuel. The fuel sensors are positionedin the interstitial spaces and in one or more of the cells of theprimary containment tank to sense a presence of fuel in the cells and aleaking of fuel from the cells into the interstitial spaces. Thesealable ports permit passage of fuel across the exterior enclosurewalls and the primary containment tank for inserting or withdrawing fuelin the cells of the primary containment tank.

In accordance with yet another embodiment, an energy generating modulecomprises an enclosure and one or more sealable ports. The enclosurecomprises a plurality of exterior enclosure walls and a plurality ofinterior enclosure walls, the exterior enclosure walls and the interiorenclosure walls cooperate to form a fuel chamber disposed between theexterior and interior enclosure walls. The fuel chamber comprises one ormore cells configured to contain fuel. The sealable ports permit passageof fuel across the exterior enclosure walls for inserting or withdrawingfuel in the cells of the fuel chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of specific embodiments can be bestunderstood when read in conjunction with the following drawings, wherelike structure is indicated with like reference numerals and in which:

FIG. 1 is an illustration of a perspective view of a power generatingmodule with baffles exposed at one end of a power generating moduleaccording to one or more embodiments;

FIG. 2 is an illustration of a perspective view of a power generatingmodule with an exposed interior of a power generating module accordingto one or more embodiments;

FIG. 3 is an illustration of a perspective view of a power generatingmodule with an exposed interior of a power generating module havinginternal walls therein according to one or more embodiments;

FIG. 4 is an illustration of a cross-sectional end view of a powergenerating module according to one or more embodiments;

FIG. 5 is an illustration of a partial cross-sectional perspective viewof a power generating module according to one or more embodiments; and

FIG. 6 is an illustration of a power generating module having a drivetrain according to one or more embodiments.

The embodiments set forth in the drawings are illustrative in nature andare not intended to be limiting of the embodiments defined by theclaims. Moreover, individual aspects of the drawings and the embodimentswill be more fully apparent and understood in view of the detaileddescription.

DETAILED DESCRIPTION

Embodiments of the present invention relate generally to energygenerating modules. These energy generating modules comprise anenclosure, an energy generating device, and a fuel chamber. The energygenerating device may utilize fuel contained in the fuel chamber togenerate an energy output. For example, but not by way of limitation,the energy generating device may be a generator engine that generateselectric power output, a boiler that generates heat and/or warm airoutput, a chiller that generates cool air output, an air compressor thatgenerates forced air output, or any other energy generating deviceconfigured to generate or otherwise produce an energy output. Solely forpurposes of simplifying the description of various embodiments of thepresent invention, the disclosure provided herein relates primarily toenergy generating modules being power generating modules that comprise apower generating device configured to generate electric power with fuelreceive from its fuel chamber. As such, the disclosure provided hereinis not limited to power generating modules and may be applied to anyenergy generating module, as described herein. Further, as used herein,the term “module” refers to any configurable enclosure, whethertransportable or fixed at a location, capable of enclosing an energygenerating device to produce an energy output for any variety orcombination of uses, or capable of storing goods or providing ahabitable space.

In some embodiments, the energy generating module may not include anenergy generating device, thereby providing the flexibility for a userto add or change one or more energy generating devices to the energygenerating module as needed. The energy generating modules describedherein may also be utilized to store equipment, parts or other goods, aswell as fuel to power external engines, vehicles or other devices. Theseembodiments may also be generally referred to herein as fuel modules.

Referring initially to FIGS. 1-6, a power generating module 10 generallycomprises a power generating device 12, an enclosure 14, one or moresealable ports 20, and a fuel chamber 22/38. The power generating device12 generally, but not necessarily, is a fuel-driven engine configured togenerate electric power. The power generating device 12 may be, forexample, a turbine engine, a reciprocating engine, an electric/gasoline(or other hybrid) engine, a combined heat and power engine (CHP), whichmay be used to direct the heat generated by the engine to a nearbyfacility for a productive use, a hydrogen fuel cell engine, asolar-powered engine, or a wind-driven engine. In fact, the powergenerating module 10 may comprise one or more of any combination ofpower generating devices 12 to enhance flexibility and/or energygeneration of the power generating module 10. With respect to theexemplary wind-driven engine embodiment, wind turbines, for example, maybe mounted onto the enclosure 14 to generate electric power, whetherduring transportation or while the power generating module 12 isstationary. With respect to the exemplary solar-powered engine, solarpanels, for example, may be provided to the roof and/or sides of theenclosure 14 to generate electric power. The power generating module 10may comprise a battery or other charge-storing device such that electricpower generated by the power generating device 12 may be discharged at alater time. The power generating device 12 is enclosed by the enclosure14 of the power generating module 10 and generally may be accessed onlyby authorized personnel.

The enclosure 14 may be any structure having a roof, a floor, a pair ofsidewalls, and a pair of end-walls that, when connected, provide achamber-like interior capable of enclosing the power generating device12, and various other components associated with generating electricpower, and of serving as a workspace for personnel. As such, theenclosure 14 may be, for example, an ISO container, a drop-overenclosure, a railway freight car, a modular home, a mobile trailer, orany other enclosure or container configured to perform the purposesdescribed herein. The enclosure 14 may be configured of any variety ofdifferent materials, such as, but not limited to, fiberglass, aluminum,stainless steel, carbon steel, or FRP (fiberglass-reinforced plastic).While the enclosure 14 generally may be configured of carbon steel, anyalternative material suitable for performing the tasks described hereinand in the art may be utilized. Further, the enclosure 14 may beattached directly to a chassis system to facilitate transportation ofthe power generating module 10 over roads or rails.

As shown in FIGS. 2-5, the enclosure 14 of the power generating module10 generally comprises a plurality of exterior enclosure walls 16 and aplurality of interior enclosure walls 18, the exterior enclosure walls16 defining an exterior of the power generating module 10 and theinterior enclosure walls 18 defining an interior of the power generatingmodule 10. These exterior and interior enclosure walls 16, 18 define,respectively, the exterior and interior roof, floor, sidewalls, andendwalls of the enclosure 14 of the power generating module 10. Whilethe exterior and interior enclosure walls 16, 18 generally are linear,it is contemplated that one or more of these walls 16, 18 may be curved.Thereby, the interior of the power generating module 10, the exterior ofthe power generating module 10, or both, may assume a circular orsemi-circular, or otherwise curved shape. Curved walls may enhance theability of the enclosure 14 to reduce the noise emanating from the powergenerating device 12 that escapes the enclosure 14 to the surroundingoutside environment. Further, curved walls may comprise one or morechannels to substantially direct noise though specially designed portsto minimize the amount noise projected to the outside environment. Theexterior and interior walls 16, 18, whether linear or curved, orcombinations thereof, cooperate to form at least a portion of the fuelchamber 22/38 of the power generating module 10.

The fuel chamber 22/38 of the power generating module 10 is configuredas an intra-wall hermetically sealed fuel chamber disposed betweenexterior and interior walls 16, 18 of the enclosure 14. Moreparticularly, the fuel chamber 22/38 may utilize the existing exteriorand interior walls 16, 18 (roof, floor, sidewalls, and endwalls) of theenclosure 14 of the power generating module 10 as one or more walls ofthe fuel chamber 22/38—whether a double-walled fuel chamber 22 orsingle-walled fuel chamber 38, as described in greater detail herein.Additional embodiments of fuel chambers are contemplated wherein thefuel chambers are configured as any multiple-wall structures, whetherdouble-wall, triple-wall, or other, that comprise a plurality ofcontainment tanks.

Creating a multipurpose role for the exterior and interior enclosurewalls 16, 18 (as well as internal walls 50, 54 described below) offersgreater flexibility in designing the fuel chamber 22/38 and the powergenerating module 10, reduces the materials and labor required to builda fuel chamber 22/38, provides additional sound attenuation due to lessexterior enclosure wall space being exposed to sources of noise (i.e.,the power generating device 12, etc.), and eliminates trip hazards whencompared with conventional power generating system fuel tanks havingperpendicular joints exposed in the interior workspace of the enclosure.With conventional fuel tanks, material, such as carbon steel, is alignedand welded together to achieve a desired size and shape of the fueltank. For conventional double-walled fuel tanks, another exterior wallis welded together and about an internal fuel tank. This increases boththe labor costs and the amount of material necessary in constructing theconventional fuel tanks. The present embodiments of the fuel chamber22/38 utilize the existing exterior and interior walls 16, 18 (roof,floor, sidewalls, and/or endwalls) of the enclosure 14 to form the fuelchamber 22/38, thereby reducing the amount of, time, material, and laborexpended in construction. Also, the configuration of embodiments of thepresent power generating module 10 with the intra-wall fuel chamber22/38, and fuel contained therein, that may substantially surround theinterior of the module 10, and the power generating device 12 storedtherein, may provide significant sound attenuation of the noisegenerated by the power generating device 12. Thereby, baffles and/orother sound-deafening materials positioned about an exterior of a powergenerating system and/or the power generating device, as commonly foundin the art, is not needed, saving additional time, material, labor, andmoney involved in construction.

Further, the fuel chamber, both double-walled 22 and single-walled 38embodiments, potentially provide significantly more cubic space for fuelcontainment given the amount of square feet along all six walls of theenclosure 14 can provide significantly more fuel capacity when comparedto conventional power generating system fuel tanks. Therefore, dependingupon the rate of fuel consumption, the runtime of the power generatingmodule 10 in generating electric power may increase significantly andmay require far fewer re-fueling trips for a fuel tanker and manpower tore-fuel the power generating module 10 in comparison to conventionalpower generating system fuel tanks.

As shown in FIGS. 4 and 5, the fuel chamber 22 of the power generatingmodule 10 may comprise a primary containment tank 24 contained within asecondary containment tank 26. This may be referred to herein as adouble-walled fuel chamber 22. The primary containment tank 24 maycomprise one or more cells 28 configured to contain fuel. The exteriorenclosure walls 16 and the interior enclosure walls 18 cooperate to formthe secondary containment tank 26 of the fuel chamber 22. Thereby, theprimary containment tank 24 is disposed between the exterior andinterior of the power generating module 10, or, more particularly,between the exterior and interior enclosure walls 16, 18, of theenclosure 14. The thickness of the primary and secondary tanks 24, 26generally is determined in accordance with the amount of fuel to becontained therein.

Alternatively, as shown in FIG. 2, the fuel chamber 38 of the powergenerating module 10 may be a single-walled fuel chamber 38 formedthrough the cooperation of the exterior and interior enclosure walls 16,18, as opposed to the fuel chamber 22 described above comprising aprimary containment tank 24 contained within a secondary containmenttank 26. More particularly, in the exemplary embodiment shown in FIG. 2,the exterior and interior enclosure walls 16, 18 cooperate to form asingle-walled fuel chamber 38. Thereby, the single-walled fuel chamber38 is disposed between the exterior and interior enclosure walls 16, 18of the power generating module 10. Similar to the double-walled fuelchamber 22, the single-walled fuel chamber 38 also may comprise one ormore cells configured to contain fuel.

Additionally, the enclosure 14 may also have one or more sets ofinternal walls that may subdivide the enclosure 14. FIG. 3 illustratesan exemplary power generating module 10 having two sets of internalwalls 50, 54. Each set of internal walls 50, 54 further comprises afirst internal wall 51 and a second internal wall 52. Similar to theexternal and interior walls 16, 18 described above, the first and secondinternal walls 51, 52 define an internal section of the fuel chamber22/38, thereby increasing the volume thereof. The internal section ofthe fuel chamber 22/38 defined by the first and second internal walls51, 52 may be in fluid communication with the sections of the fuelchamber 22/38 defined by the exterior and interior walls 16, 18. Theinternal walls 50, 54 may be of single-walled, doubled-walled and/ormultiple-walled configurations as described above.

The internal walls 50, 54 may also subdivide the enclosure 14 intoseparate enclosure sections 14 a-14 c that may be used for any number ofpurposes. For example and not limitation, a first type of energygenerating device may be enclosed in enclosure section 14 a, a secondtype of energy generating device may be enclosed in enclosed section 14b, and a living quarters or storage space may be maintained in enclosuresection 14 c. A plurality of doors 44 a-44 c and louvers 40 a-40 c mayalso be provided to provide access and ventilation to the enclosuresections 14 a-14 c.

In some embodiments, the exterior and interior walls may be defined byassembled modular panels configured to hold fuel and form the enclosure14. Complementary modular panels may be interconnected to form anenclosure 14 for the energy generating device 10 or other storedequipment or goods. “Modular” panels are panels that can interconnect ina variety of configurations, for a variety of purposes, to form part orall of an enclosure 14. For example, modular panels can simply serve asmulti-purpose wall panels suitable for use in any part of an enclosurewall or, at a more sophisticated extreme, can serve as wall panels indifferent parts of an enclosure wall, as ceiling panels in differentparts of an enclosure ceiling, as louver panels, window-abutting panels,door panels, corner panels, floor panels, etc. As an example and not alimitation, the modular panels may be configured as the modular panelsdisclosed in U.S. patent application Ser. No. 12/205,442.

With respect to the double-walled fuel chamber 22, the primary andsecondary containment tanks 24, 26 may be separated by one or moreinterstitial spaces 32. The width of the interstitial space 32 betweenthe primary and secondary containment tanks 24, 26 may be determined byregulations or industry standards. While the primary containment tank 24may be hermetically sealed to substantially preclude fuel leakagetherefrom, leakage may occur due to a manufacturing defect in the powergenerating module 10, a compromising of the exterior and interiorenclosure walls 16, 18 from collision with or puncturing by a foreignobject, or other reason. As such, the interstitial spaces 32 may beconfigured to collect fuel that may leak from the primary containmenttank 24. It is also contemplated that the secondary containment tank 26may also be hermetically sealed so as to substantially preclude fuelleakage from the interstitial spaces 32 across the exterior and/orinterior enclosure walls 16, 18.

In addition, one or more of the interstitial spaces 32 may be at leastpartially filled with concrete, insulation, or other matter to furtherattenuate noise emanating from the power generating device 12 and torestrict the puncturing of both the primary and secondary containmenttanks 24, 26 with a foreign object. This insulating matter may befurther configured or provided in such a way within the interstitialspaces 32 to permit a flow of fuel therethrough so as not to obstructfuel from appropriate sensing by the power generating module 10, asdescribed in greater detail below. The interstitial spaces 32 may alsopermit the storage of other materials, such as batteries or other goods.The term “goods” is defined as any item that may be used or consumed,such as equipment, food, clothing, tools, batteries, etc. Further,dimensions of the interstitial spaces 32 may be maintained by a bracethat may be welded perpendicularly to the walls of the primary andsecondary containment tanks 24, 26 (i.e. the exterior and interiorenclosure walls 16, 18). This brace may be configured to support thesewalls and to allow fuel to pass therethrough should there be a leak inthe primary containment tank 24.

In some embodiments portions of the exterior and interior enclosurewalls 16, 18 may be made of a transparent material such as temperedglass or plastic, for example, so that at least some external light mayenter the enclosure 14. The transparent portions of the walls 16, 18 mayprovide a means for fuel level detection (i.e., a sight glass) withoutthe need for an electronic or mechanical fuel gauge. Further, dependingon the type of fuel stored within the fuel chamber 22/38, thetransparent portions may enable light to enter the enclosure 14.

As shown in FIG. 4, the power generating module 10 may comprise one ormore fuel sensors 34 positioned in the interstitial spaces 32 to sense apresence of fuel therein due to a leak in the primary containment tank24. The interstitial spaces generally are configured to direct fuelcollected therein to a position of the fuel sensor for sensing. Also,the power generating module 10 may comprise one or more fuel sensors inthe cells 28 of the primary containment tank 24 or in the cells of thesingle-walled fuel chamber 38 to sense levels of fuel contained thereinand to notify an operator of the power generating module 10 of a need tore-fuel.

The cells 28 within the primary containment tank 24 and the cells withinthe single-walled fuel chamber 38 may be configured to contain,cumulatively or independently, any desirable amount of fuel. In oneexemplary embodiment, the cells 28 in the primary containment tank 24are configured to contain cumulatively about 1,500 gallons of fuel in a20 foot standard ISO container having a double-walled fuel chamber 22with about 150% containment, whereas, a conventional fuel tank in a 20foot standard ISO container generally holds only about 750 gallons and,thus, provides only about 50% of the runtime of the power generatingdevice in comparison to the present exemplary embodiment. Further, inanother exemplary embodiment, the cells 28 are configured to containcumulatively about 3,000 gallons of fuel in a 40 foot standard ISOcontainer having a double-walled fuel chamber 22 with about 150%containment, whereas, a conventional fuel tank in the same sizedcontainer generally holds only about 1,500 gallons. In addition, withrespect to additional exemplary embodiments of double-walled fuelchambers 22 that provide about 200% containment, the cells 28 may beconfigured to contain cumulatively about 1,100 gallons of fuel in a 20foot standard ISO container or about 2,200 gallons of fuel in a 40 footstandard ISO container. Conversely, conventional fuel tanks generallyhold only about 550 and 1,100 gallons of fuel in 20 foot and 40 footstandard ISO containers, respectively. Therefore, embodiments ofdouble-walled fuel chambers 22 may provide about 200% of the fuelstorage capacity generally available with conventional fuel tanks. It isanticipated that embodiments of single-walled fuel chambers 38 describedherein may provide even greater than 200% of the fuel storage capacitygenerally available with conventional fuel tanks as a limiting factor tofuel storage capacity for conventional fuel tanks is their respectiveheights, which, with the fuel tanks being confined within an interiorspace of the enclosure, is restricted by the height of the interiorworkspace within the enclosure.

In addition, not only may the primary containment tank 24 and thesingle-walled fuel chamber 38 be hermetically sealed, as describedabove, but, also, the cells respective to the primary containment tank24 and the single-walled fuel chamber 38 may be individuallyhermetically sealed so as to substantially preclude fuel leakage betweenthe cells and from the cells into the interstitial spaces 32 or acrossthe exterior enclosure walls 16. Two or more of the cells may also befluidly interconnected such that fuel may flow through theinterconnected cells. In addition, one or more cells of the fuelchambers 22/38 of one power generating module 10 may be connected to oneor more cells of the fuel chambers 22/38 of another nearby powergenerating module 10. Thereby, a plurality of interconnected powergenerating modules 10 may be provided to produce a greater, cumulativeelectric power output than available through a single, isolated powergenerating module 10. For example, but not by way of limitation,multiple adjacent power generating modules 10 in fluid communication andall configured to and capable of sharing fuel contained in theirrespective fuel chambers 22/38 through fuel conveying devices, such ashoses, tubes, valves, clamps, etc., may be provided. Further, it iscontemplated that power generating modules 10 supported on chassis orrailcars for purposes of transportation may be connected to a tankertruck or tanker railcar that may contain several thousand gallons offuel in addition to that contained in the fuel chambers 22/38.

Further, the cells may be supported internally by a plurality of baffles30 intermittently welded or continuously welded inside of the cells, asshown in FIGS. 1-4. The baffles 30 may be configured to maintainpredefined dimensions of the cells. The baffles 30 may be perforated soas to permit passage of fuel therethrough. Further, the baffles 30 maybe configured and/or positioned within the cells to further attenuatenoise emanating from the power generating device 12. Sound insulatingmatter, such as, but not limited to concrete, insulation, or othermatter, may also be provided internally to the cells to provideadditional noise attenuation benefits while not significantlyinterfering with a flow of fuel within the cells.

As mentioned above, the power generating module 10 also comprises one ormore sealable ports 20. The sealable ports 20 may be configured topermit passage of fuel across the exterior enclosure walls 16 and theprimary containment tank 24 for inserting or withdrawing fuel in thecells of the primary containment tank 24 and the single-walled fuelchamber 38. The sealable ports 20 generally are positioned above amaximum level of fuel contained in the cells so as to preclude leakageof fuel to outside of the enclosure 14 through the sealable ports 20. Itis contemplated, however, that the sealable ports 20 may be positionedat any location on the power generating module 10. In an embodimentwhere a sealable port 20 is positioned beneath a maximum level of fuelcontained in the cells, the sealable port 20, the fuel chamber 22/38, orboth, may be configured to prevent, or substantially prevent, fuel fromflowing back into and/or through the sealable port 20, therebyprecluding leakage of fuel to outside of the enclosure 14 through thesealable port 20.

The provision of multiple sealable ports 20 to the power generatingmodule 10 offers greater re-fueling flexibility, if access to a sealableport 20 is obstructed or otherwise prevented, and may reduce the timenecessary for re-fueling. It is contemplated that where multiple,independent cells are within the primary containment tank 24 or thesingle-walled fuel chamber 38, a sealable port 20 may be provided toeach cell. Thereby, in such embodiments, the independent cells may befilled simultaneously with a common fuel or with various types of fuel,further reducing the time necessary to re-fuel the power generatingmodule 10. Further, with respect to re-fueling a power generating module10, it is contemplated that the fuel may be delivered and provided byany variety of fuel sources. For example, the fuel may be provided by atanker trailer or a tanker railcar that is transported to the locationof the power generating module 10. By way of another example, the powergenerating module 10 itself may be transported to a fuel station or astationary or immobilized tanker to which the power generating module 10may couple to receive fuel.

Further, the power generating module 10 may comprise one or more fuelconveying devices 36 for conveying fuel from the cells of the primarycontainment tank 24 and the single-walled fuel chamber 38 to the powergenerating device 12. Thereby, the power generating device 12 enclosedwithin the interior of the power generating module 10 is in fluidcommunication with the cells via the fuel conveying devices 36. Thepower generating device 12 may then generate electric power with fuelreceived from the cells by the fuel conveying devices 36. The fuelconveying devices 36 may include, but are not limited to, one or moretubes, hoses, clamps, valves, seals, and/or other additional or similardevices.

In addition, the power generating module 10 may comprise a normal ventand an emergency vent. The primary containment tank 24 and the exteriorenclosure wall 16 of the single-walled fuel chamber 38 generally havelocated on their respective top surfaces both normal and emergency ventsthat may be used to automatically relieve internal gaseous pressure. Thesecondary containment tank 26 generally has located at its top surfacean emergency vent to relieve excessive pressure that has developedwithin primary and secondary containment tanks 24, 26 often due toexternal fire exposure or blockage of the normal vent.

Further, it is contemplated that a substantially impenetrable coating orother material may be applied to one or more walls of a fuel chamber ortank that may render the need for double walls, interstitial spaces,and/or secondary tanks unnecessary. More particularly, the coating maysubstantially prevent projectiles or other foreign objects from piercingthe wall of a fuel chamber or tank. This coating, if applied to thewalls of a fuel chamber or tank, may eliminate the need for thesecondary containment and any protective or insulating material providedtherein. This further reduces materials, time, labor, and costs ofconstruction of power generating modules 10 and permits expansion of thefuel chamber to larger dimensions for increased storage of fuel in lieuof the interstitial spaces. The coating may be applied as a liquid thatdries to a substantially impenetrable material about the walls of thefuel chamber or tank. Alternatively, the coating may be a materialaffixed or otherwise provided about the walls of the fuel chamber ortank while in its impenetrable condition, such as in a slab or packagedconfiguration. It is also contemplated that the coating may assist inattenuating noise generated by the power generating device 12.

Fuel utilized by the power generating module 10 and contained in thecells in the fuel chambers 22/38 may be contained in a compressed or anon-compressed state. In addition, fuel utilized by the power generatingmodule 10 and contained in the cells in the fuel chambers 22/38 is notlimited to any particular fuel type. Rather, the fuel may be, but is notlimited to, any petroleum-based fuel, such as gasoline, propane, diesel,jet fuel, kerosene, or liquefied natural gas, any biofuel, or hydrogen.In some embodiments, the fuel chamber 22/38 and/or portions of theenclosure 14 may be pressurized such that energy requiringpressurization such as gasses may be stored within the power generatingmodule 10. For example, refrigerants may be stored within one or morecells of the fuel chamber 22/38 in an embodiment of the power generatingmodule that utilizes a chiller or cooler. It is contemplated that anypressurized gas or energy source may be stored within the fuel chamber22/38 and/or portions of the enclosure 14.

As described above, individually sealed cells of the fuel chambers 22/38may contain different types of fuels. This permits not only electricpower generation, but also re-fueling of vehicles that utilize variousfuel types. In accordance with embodiments configured to permitrefueling of vehicles with fuel dispensed from a fuel chamber 22/38 of apower generating module 10, the power generating module 10 may compriseone or more fuel dispensing receptacles in fluid communication with thefuel in the fuel chamber 22/38 and configured to be applied to a vehiclefor dispensing fuel into the vehicle's fuel tank. Fuels used to supply avehicle may include, but are not limited to, gasoline, diesel, bio-fuel,and hydrogen. Thereby, not only may a power grid or other electricalsystem be powered by the power generating device 12, but a vehicleutilizing any one of a variety of fuel types may be re-fueled with fuelin the fuel chamber 22/38 at the same power generating module 10.Embodiment may also comprise one or more energy-transfer receptacles tocharge and/or power external equipment. For example, energy-transferreceptacles may be provided to charge the batteries or other energysources of a vehicle or power an electric motor or other device.Multiple energy-transfer receptacles may be provided such that multiplevehicles or other types of equipment may be charged/powered concurrentlyor charge more quickly than with a single energy-transfer receptacle.For example, an electric vehicle may be configured to receive electricalpower from a plurality of sources to reduce charge time. Rather then onelarge battery system that may require a lengthy period of time in whichto replenish (e.g., twenty four hours), the electric vehicle may beconfigured to have twelve battery systems that may be independentlycharged within a relatively shorter period of time (e.g., two hours).The power generating module 10 may include several energy-transferreceptacles to connect to all twelve battery systems, for example.Embodiments may utilize any conventional or yet-to-be-developedconfiguration of fuel dispensing and energy-transfer receptacles. As anexample, the fuel dispensing and energy transfer receptacles may beconfigured as those disclosed in U.S. patent application Ser. No.12/205,437.

In addition, the storage of various fuel types also enables the powergenerating device 12 of the power generating module 10 to be powered byone or more of any variety of fuel types to generate electric power. Asdiscussed above, multiple energy generating devices may be providedwithin a energy or power generating module 10. The sealed and separatedfuel cells may enable a first type of energy generating device, such asa diesel engine, for example, to be in fluid communication with a firsttype of fuel, and a second energy generating device, such as a chiller,for example, to be in fluid communication with a second type of fuel. Itshould be understood that more than two types of fuel and energygenerating devices may be provided within the power generating module10. In this manner, embodiments of the power generating device 10 mayprovide fuel to different types of equipment having different fuelrequirements.

With the power generating module 10 comprising a power generating device12 and a fuel chamber 22/38, along with other components necessary forthe generation of electric power, the power generating module 10 isself-contained and is independent of any outside resources, with theexception of re-fueling the fuel chamber 22/38, that may be needed togenerate and discharge electric power and/or fuel. Thereby, the powergenerating module 10 may operate independently of personnel, outside ofoccasional temporary maintenance, refueling, power gridconnection/disconnection, and transportation of the power generatingmodule 10. Remaining operations of the power generating module 10 may beself-performed by the power generating modules 10 or may be controlledand/or monitored remotely. With respect to the re-fueling of vehicles,according to one exemplary embodiment, vehicle operators may park theirvehicles along side a power generating module, couple a fuel dispensingreceptacle of the power generating module to their vehicles, anddispense fuel from the fuel tank of the power generating module 10 tothe vehicle for refueling purposes. Further, the power generatingmodules 10 may be configured such that vehicle operators may to transactfuel purchases through credit card or other payment transactions,eliminating the need for personnel on site to handle paymentarrangements. For example, but not by way of limitation, vehicleoperators may swipe a credit cards in a card-reading mechanism affixedto and/or linked with the power generating module 10 to pre-pay for thefuel, as currently offered at most fueling stations.

As mentioned above, the power generating module 10 generally comprisescomponents in addition to the power generating device 12 that may benecessary for, or facilitative of, electric power generation. Theseadditional components may include, but are not limited to: analternator, a battery or other charge storing device, DC lightingsystems, electrical controls such as engine switchgear or a voltagechangeover board, sound attenuation, fire suppression systems, personneldoors, fuel tank, louvers for ventilation, fan cooling system, and anexhaust system. Any combination of these items may be considered to be apower generating module 10. The exhaust system may be configured toinclude environmentally-friendly scrubbers to remove, or substantiallyremove, toxic or harmful substances from the exhaust generated by thepower generating device 12 of the power generating module 10, such asNOx. Further, for construction of the power generating module 10, thepower generating device 12, alternator, electrical controls, aircirculation, exhaust systems, and other components may be manufacturedin and/or provided by separate facilities. Once constructed andappropriately configured, the power generating device 12 may be placedwithin an interior of the power generating module 10.

Further, the enclosure 14 of the power generating module 10 may beconfigured to enclosure and support a modular cage. This modular cagemay be configured to stably support the power generating device 12, andpossibly other components positioned within the interior of theenclosure 14, such as but not limited to, a radiator and an alternatorintegrated into the power generating device 12, during transportation ofthe power generating module 10 over roads or rails. More particularly,the power generating device 12 may be supportedly affixed to the cagewith the assembly thereof being placed into the interior of theenclosure 14. The cage may support the power generating device 12 suchthat while the cage is secured within the interior of the enclosure 14,the power generating device 12 may sway within the boundaries of thecage so as to be self-leveling with the movement of the power generatingmodule 10 during transportation. By way of example only, the cage mayfunction similarly to a gyroscope in maintaining stability throughadjustable self-leveling. In addition, or alternative thereto, the cagemay comprise an independent suspension within the interior of theenclosure 14 to provide self-leveling capabilities to the cage and thepower generating device 12. As such, the modular cage may protect thepower generating device 12, and any other components supported by thecage, from damage during transportation, may substantially reducetilting of a trailer or rail car transporting the power generatingmodule 10. The modular cages may be designed to fit securely within, andaccording to the dimensions of, an interior of an enclosure 14. Inaddition, the cages may be designed for repeated, rapid insertion andwithdrawal to and from an interior of an enclosure 14. For example, oneor more guide rails may be secured to the flooring of the interior ofthe enclosure 14 to receive and lock into place modular cage containinga power generating device 12 and electronic controls. Such features ofthe module cage permit greater flexibility of the power generatingmodules 10 and the use of its components, which may be interchangeablewithin enclosures 14 and power generating modules 10, assuming a“plug-and-play” configuration.

As shown in FIGS. 1-5, the power generating module 10 may also compriselouvers 40 for ventilation, a doorway 42, and a door 44 for access tothe internally enclosed power generating device 12. More particularly,portions of the exterior and interior enclosure walls 16, 18 of theenclosure 14 may comprise a plurality of closable louvers 40 and adoorway 42 for personnel to access the power generating device 12. Inaddition to the louvers 40, the power generating modules 10 may alsocomprise a fan cooling system to cool the power generating device 12.The louvers 40 and/or the cooling system may be configured to draw airin from a roof, ends, and/or sides of the enclosure 14. Suchconfigurations may ensure that there is sufficient air flow to supportand cool the power generating device 12 and assist with exhaust.Further, such configurations may adequately cool an interior workspacearea of the enclosure 14 to permit access by personnel.

Further, while the chambers 22/38 described herein are referred to as“fuel chambers,” it is contemplated that the chambers may be used forpurposes other than, or in addition to, containing fuel. In fact, thechambers may be used to contain any fluid, liquid or gas. In addition,the chambers may provide hollow spaces accessible from the interiorand/or exterior of the enclosure 14 in which various goods and/orsupplies may be stored. Also, the chambers may contain insulation fortemperature regulating purposes and/or insulation or other material forsound attenuation or reduction purposes. Further, for example, it iscontemplated that some chambers may contain fuel, while other chamberswithin the same enclosure 14 contain insulation, sound reduction panels,supplies, a ladder to facilitate access to the interior of theenclosure, batteries, water, human or mechanical waste, and/or may beinternally divided into distinct cells that contain one or more of theabove, or other goods, and any combinations thereof.

It is contemplated that two or more power generating modules 10 may besituated side-by-side or in near locations, whether on adjacent trailerchassis, on a concrete pad or other ground surface, or on a single ormultiple railway cars. The provision of multiple power generatingmodules 10 in a single location may enable the continuous provision ofelectric power when a power generating module 10 is inoperable due tore-fueling, maintenance, or other reason, and the simultaneous provisionof electric power, whether individually, in various combinations, orcumulatively by the multiple power generating modules 10. Further, whensituated on a single or multiple railway cars, the power generatingmodules 10 may be situated side-by-side, stacked on top of each other,or both, to facilitate transportation of the modules 10 and to providegreater and/or more versatile electric power output with multiple powergenerating modules 10.

A plurality of energy generating modules 10 that are spread over ageographic area (e.g., a power generating module, fuel module, etc.) maybe electrically coupled together via one or more network monitoringstations to form a network. Conditions of the coupled energy generatingmodules 10 may be monitored and controlled by the network monitoringstations, which may comprise a general purpose computer configured toreceive and transmit data to and from the plurality of energy generatingmodules or other dedicated hardware and software. The conditions of theenergy generating modules 10 monitored by the network monitoring stationmay comprise any variety of conditions related to energy transfer,operation, use, performance, other conditions, and combinations thereof.The network may be configured as the energy generating module networkdisclosed in U.S. patent application Ser. No. 12/205,437, for example.It is contemplated that other network configurations may also beutilized.

To further facilitate transportation of the power generating modules 10,in some embodiments the power generating module 10 may be equipped suchthat the module 10 may be driven and easily transported to a variety oflocations. FIG. 6 illustrates an exemplary power generating module 100with an incorporated drive train 60. The drive train 60 may be an enginesystem and associated cab (e.g., a truck) configured such that the powergenerating module 100 may be driven to a desired location. The drivetrain 60 may have its own source of fuel (e.g., a dedicated fuel tank)or draw on the fuel contained in the fuel chamber(s) 22/38.

Having a drive train 60 incorporated into the power generating module100 may eliminate the need for the power generating module to be towedby a tractor such as a semi-truck, and may also speed the delivery ofthe power generating module to the desired location. For example, duringan emergency situation, such as a natural or man-made disaster, forexample, semi-trucks and trailers capable of transporting a powergenerating module 10 may be in high-demand and short supply. A fleet ofpower generating modules 100 having an associated drive train 60 may bequickly deployed to the disaster site to provide energy to the disastervictims and support personnel. Further, embodiments of the powergenerating module 100 may be driven to a refueling location rather thenrequiring a fueling truck to be driven to the power generating site,which may reduce refueling costs.

Although the embodiment illustrated in FIG. 6 comprises a drive train60, vehicular embodiments are not limited thereto. For example, thepower generating module 10 may comprise integrated axles and wheels suchthat the module 10 may be towed by a tractor. Having integrated axlesand wheels eliminates the need to secure a trailer to transport thepower generating module 10, which may reduce deployment time.Additionally, the power generating module 10 may further compriseintegrated skids and/or skis having a substantially flat surface suchthat the module 10 may be driven or towed in snowy conditions.

Further, it is contemplated that not only may the power generatingmodules 10 be used for industrial, construction, mining, oil and gasexploration, and commercial applications, as described herein, but thepower generating modules 10 may be used for marine applications as well.More particularly, a power generating module 10 may be positioned on adock, wharf, or other water-side location such that the module 10 mayprovide electric power to a ship, boat, or other water vessel to chargean energy storage device of the vessel or to re-fuel the vessel with afuel contained within the fuel chamber 22/38 of the module 10. Inaddition, a power generating module 10 may be placed on-board of a watervessel to provide prime or back-up electric power for the vessel and/orfor fuel for vehicles also on-board of the vessel. Further, a powergenerating module 10 may be secured to a floatation device fortransportation over water, which may enable the power generating module10 to be transported to a location that is not easily accessible byland. The floatation device may be any device capable of supporting apower generating module 10, such as an inflatable floatation device, apontoon style boat, or outrigger raft, for example.

A power generating module 10 may also be configured as a habitableenclosure for persons to live, work and perform other activities. Forexample, the enclosure 14 may define a livable space having a bed,furniture, plumbing, lighting, electrical systems, cooking equipment,etc. The power generating module 10 may be configured as an emergencytrailer that provides emergency shelter, a mobile home, a module home, aprefabricated home, etc. The power generating modular 10 may be usedsolely for sheltering individuals or it may also be used to bothgenerate power with a power generating device as well as shelter peopleand/or store goods. Power generating modules 10 defining a livable spacemay be beneficial to persons working in remote locations as they mayprovide shelter as well as fuel and power.

It should be noted that embodiments of the fuel chamber 22/38 describedherein do not attempt to improve upon existing fuel containmentregulations, standards, or guidelines, such as the UnderwritersLaboratories Inc.'s standards (see UL 142 and 2085). Further, it iscontemplated that the power generating modules 10 and the fuel chambers22/38 may be configured and manufactured in accordance with UL standards142, 2085, and/or any other standards, regulations, or guidelines.

It is noted that recitations herein of a component of an embodimentbeing “configured” in a particular way or to embody a particularproperty, or function in a particular manner, are structural recitationsas opposed to recitations of intended use. More specifically, thereferences herein to the manner in which a component is “configured”denotes an existing physical condition of the component and, as such, isto be taken as a definite recitation of the structural characteristicsof the component.

It is noted that terms like “generally” and “typically,” when utilizedherein, are not utilized to limit the scope of the claimed embodimentsor to imply that certain features are critical, essential, or evenimportant to the structure or function of the claimed embodiments.Rather, these terms are merely intended to identify particular aspectsof an embodiment or to emphasize alternative or additional features thatmay or may not be utilized in a particular embodiment.

For the purposes of describing and defining embodiments herein it isnoted that the terms “substantially” and “approximately” are utilizedherein to represent the inherent degree of uncertainty that may beattributed to any quantitative comparison, value, measurement, or otherrepresentation. The terms “substantially” and “approximately” are alsoutilized herein to represent the degree by which a quantitativerepresentation may vary from a stated reference without resulting in achange in the basic function of the subject matter at issue.

Having described embodiments of the present invention in detail, and byreference to specific embodiments thereof, it will be apparent thatmodifications and variations are possible without departing from thescope of the embodiments defined in the appended claims. Morespecifically, although some aspects of embodiments of the presentinvention are identified herein as preferred or particularlyadvantageous, it is contemplated that the embodiments of the presentinvention are not necessarily limited to these preferred aspects.

1. A fuel module comprising an enclosure and a fuel chamber, wherein:the fuel chamber comprises a primary containment tank contained within asecondary containment tank, the primary and secondary containment tanksseparated by one or more interstitial spaces; the primary containmenttank of the fuel chamber comprises one or more cells configured tocontain fuel; the enclosure comprises a plurality of exterior enclosurewalls and a plurality of interior enclosure walls; and the exteriorenclosure walls and the interior enclosure walls cooperate to form thesecondary containment tank of the fuel chamber such that the primarycontainment tank is disposed between the exterior enclosure walls andthe interior enclosure walls.
 2. The fuel module of claim 1, wherein thecells of the primary containment tank are individually hermeticallysealed such that the fuel module is configured to contain more than onetype of fuel.
 3. The fuel module of claim 1, wherein the fuel module isconfigured to enclose goods.
 4. The fuel module of claim 1, wherein atleast a portion of the exterior enclosure walls and the interiorenclosure walls is transparent.
 5. The fuel module of claim 1 furthercomprising a fuel dispensing receptacle in fluid communication with atleast some of the cells within the primary containment tank.
 6. The fuelmodule of claim 1 further comprising a first energy generating device,wherein the first energy generating device is enclosed by the interiorenclosure wall of the enclosure, is in fluid communication with thecells of the primary containment tank, and is configured to generate anenergy output with fuel received from the cells.
 7. The fuel module ofclaim 6, wherein the first energy generating device comprises a powergenerating device configured to generate electrical power.
 8. The fuelmodule of claim 7 further comprising a plurality of energy-transferringreceptacles coupled to the power generating device.
 9. The fuel moduleof claim 6 further comprising an additional energy generating device,wherein the additional generating device is enclosed by the interiorenclosure wall of the enclosure, is in fluid communication with thecells of the primary containment tank, and is configured to generate anenergy output with fuel received from the cells.
 10. The fuel module ofclaim 9, wherein: at least some of the cells of the primary containmenttank are individually hermetically sealed such that one or more cells ofthe fuel module is configured to contain a first fuel type and one ormore cells of the fuel module is configured to contain a second fueltype; and the first energy generating device is in fluid communicationwith the cells configured to contain the first fuel type; and theadditional energy generating device is in fluid communication with thecells configured to contain the second fuel type.
 11. The fuel module ofclaim 1, wherein the cells are configured to contain one or more of thefollowing: gasoline, propane, diesel, jet fuel, kerosene, liquefiednatural gas, biofuel, hydrogen, human waste, pressurized gas, and water.12. The fuel module of claim 1 further comprising one or more sealableports, wherein the sealable ports permit passage of fuel across theexterior enclosure walls and the primary containment tank for insertingor withdrawing fuel in the cells of the primary containment tank. 13.The fuel module of claim 1 further comprising one or more first internalwalls and one or more second internal walls positioned within theenclosure, wherein the first and second internal walls cooperate to forman internal section of the secondary containment tank of the fuelchamber such that an internal portion of the primary containment tank isdisposed between the first and second interior walls.
 14. The fuelmodule of claim 1, wherein the enclosure defines a livable space. 15.The fuel module of claim 1 is configured to be driven from a firstlocation to a second location.
 16. The fuel module of claim 1 furthercomprising a drive train.
 17. The fuel module of claim 1 furthercomprising at least one substantially flat ski surface positioned on anunderside surface of the power generating module.
 18. The fuel module ofclaim 1, wherein one or more of the interstitial spaces are at leastpartially filled with concrete, insulation, electrical batteries, orother matter.
 19. The fuel module of claim 1, wherein the fuel module iselectrically coupled to a network comprising at least one additionalfuel module.
 20. The fuel module of claim 1, wherein the plurality ofexterior and interior walls comprises a plurality of modular panelshaving fuel chambers that are configured to contain fuel.
 21. The fuelmodule of claim 1, further comprising one or more sealable ports, andone or more fuel sensors, wherein: the fuel chamber comprises a primarycontainment tank contained within a secondary containment tank; theenclosure comprises a plurality of exterior enclosure walls and aplurality of interior enclosure walls; the exterior enclosure walls andthe interior enclosure walls cooperate to form the secondary containmenttank of the fuel chamber such that the primary containment tank isdisposed between the exterior enclosure walls and the interior enclosurewalls; the primary containment tank of the fuel chamber comprises one ormore cells configured to contain fuel; the fuel sensors are configuredto sense a presence of fuel; and the sealable ports permit passage offuel across the exterior enclosure walls and the primary containmenttank for inserting or withdrawing fuel in the cells of the primarycontainment tank.
 22. The fuel module of claim 1, further comprising oneor more sealable ports, wherein the sealable ports permit passage offuel across the exterior enclosure walls for inserting or withdrawingfuel in the cells of the fuel chamber.